Disposable pull-on garment having improved protection against red marking and method for making the same

ABSTRACT

The present disclosure is directed, in part, to a disposable garment having a front region, a back region, and a crotch region extending between the front region and the back region. The disposable garment comprises a chassis in the front region, the back region, and the crotch region. The chassis comprises a liquid pervious topsheet, a liquid impervious backsheet, and an absorbent core disposed between the topsheet and the backsheet. The disposable garment comprises a pair of ear panels extending laterally outward from the chassis in the front region or the back region, a seam panel extending laterally outward from at least one of the ear panels, and a tab formed with the seam panel and extending laterally outward from the seam panel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.14/268,170, filed on May 2, 2014, which is a continuation of U.S. patentapplication Ser. No. 13/599,341, filed on Aug. 30, 2012, which is acontinuation of U.S. patent application Ser. No. 10/366,176, filed onFeb. 13, 2003, now U.S. Pat. No. 8,257,334, which is a divisional ofU.S. patent application Ser. No. 09/700,559, filed on Nov. 16, 2000, nowabandoned, which was the National Stage Entry of InternationalApplication Serial No. PCT/US98/10841, filed on May 28, 1998, the entiredisclosures of each are hereby incorporated by reference in theirentirety.

FIELD

The present invention relates to disposable garments.

BACKGROUND

Infants and other incontinent individuals wear disposable garments suchas diapers to receive and contain urine and other body exudates.Disposable pull-on garments having fixed sides, which are also called“pant type” garments, have become popular for use on children able towalk and often who are toilet training These pull-on garments have sidepanels with edges that are seamed together to form two leg openings anda waist opening. In order to contain body exudates as well as fit a widevariety of body shapes and sizes, these pull-on garments need to fitsnugly about the waist and legs of the wearer without drooping, saggingor sliding down from its position on the torso. Examples of thesepull-on garments are disclosed, for example, in U.S. Pat. No. 5,171,239issued to Igaue et al. on Dec. 15; 1992, U.S. Pat. No. 4,610,681 issuedto Strohbeen et al. on Sep. 9, 1986; U.S. Pat. No. 4,940,464 issued toVan Gompel et al. on Jul. 10, 1990; U.S. Pat. No. 5,246,433 to issuedHasse et al. on Sep. 21, 1993; U.S. Pat. No. 5,569,234 issued to Buellet al. on Oct. 29, 1996; and WO 96/31176 (Ashton) published on Oct. 10,1996.

To prevent pull-on garments from drooping, sagging or sliding down fromthe torso of wearer, it is believed that a proper force should begenerated at the waist and side panel areas of pull-on garments andapplied to the torso of the wearer. For example, U.S. Pat. No. 5,415,649issued to Watanabe et al. on May 16, 1995, discloses the use of elasticmembers which have different expanding stresses to provide a better fitto body. Another example is EP 0547497B1 (Van Gompel et al.) publishedon Mar. 26, 1997. This publication discloses a disposable training pantwhich has stretch gradient side panels to provide an improved fitness.Those conventional pull-on garments try to provide an improved fitnessto the body of wearer by controlling forces applied to the waist and legareas of wearer. However, the improvement in fitness may cause a redmarking problem at those areas.

Japanese Laid-Open Patent Publication H8-38546 published on Feb. 13,1996 discloses a pant type disposable diaper which has a slit formed bynot connecting leg portion elastics at the leg opening, to preventmarking of the skin by the leg portion elastics. However, this pull-ongarment has a unextensible backsheet in the side panels, which tends toprevent the pull-on garment from providing an improved fitness.

Thus, none of the existing art provides all of the advantages andbenefits of the present invention.

SUMMARY

In an embodiment, the present disclosure is directed, in part, to adisposable garment having a front region, a back region, and a crotchregion extending between the front region and the back region. Thedisposable garment comprises a chassis in the front region, the backregion, and the crotch region. The chassis comprises a liquid pervioustopsheet, a liquid impervious backsheet, and an absorbent corepositioned between the topsheet and the backsheet. The disposablegarment further comprises a pair of extensible ear panels extendinglaterally outward from the chassis in the front region or the backregion, wherein the liquid impervious backsheet does not extend to theextensible ear panels.

In another embodiment, the present disclosure is directed, in part, to adisposable garment having a front region, a back region, and a crotchregion extending between the front region and the back region. Thedisposable garment comprises a chassis in the front region, the backregion, and the crotch region. The chassis comprises a liquid pervioustopsheet, a liquid impervious backsheet, and an absorbent corepositioned between the topsheet and the backsheet. The disposablegarment comprises a pair of extensible ear panels extending laterallyoutward from the chassis in the front region or the back region, whereinthe liquid impervious backsheet is separate from the extensible earpanels.

In still another embodiment, the present disclosure is directed, inpart, to a laminate structure comprising a first coverstock layer, asecond coverstock layer, an elastomeric material positioned intermediatethe first coverstock layer and the second coverstock layer, a firstanchor zone comprising a first bonding pattern positioned in a firstedge area of the laminate structure, a second anchor zone comprising thefirst bonding pattern positioned in a second edge area of the laminatestructure, and a second bonding pattern intermediate the first andsecond anchor zones.

In yet another embodiment, the present disclosure is directed, in part,to a disposable garment having a front region, a back region, and acrotch region extending between the front region and the back region.The disposable garment comprises a chassis in the front region, the backregion, and the crotch region. The chassis comprises a liquid pervioustopsheet, a liquid impervious backsheet, and an absorbent core disposedbetween the topsheet and the backsheet. The disposable garment comprisesa pair of ear panels extending laterally outward from the chassis in thefront region or the back region, a seam panel extending laterallyoutward from at least one of the ear panels, and a tab formed with theseam panel and extending laterally outward from the seam panel.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the invention, it is believed that the inventionwill be better understood from the following description of preferredembodiments which is taken in conjunction with the accompanying drawingsand which like designations are used to designate substantiallyidentical elements, and in which:

FIG. 1 is a perspective view of one preferred embodiment of thedisposable pull-on garment of the present invention in a typical in useconfiguration;

FIG. 2 is a perspective view of another preferred embodiment of thedisposable pull-on garment of the present invention in a typical in useconfiguration;

FIG. 2A is a perspective view of another preferred embodiment of thedisposable pull-on garment of the present invention in a typical useconfiguration;

FIG. 2B is a perspective view of another preferred embodiment of thedisposable pull-on garment of the present invention in a typical useconfiguration;

FIG. 3 is a simplified plan view of the embodiment shown in FIG. 2 inits flat uncontracted condition showing the various panels or zones ofthe garment;

FIG. 4 is a cross-sectional view of a preferred embodiment taken alongthe section line 4-4 of FIG. 3;

FIG. 5 is a more detailed plan view of the front and back ear panels 46and 48 which are shown in FIG. 2;

FIG. 6 is a cross-sectional view of an elastic member 70 of a preferredembodiment;

FIG. 7 is a fragmentary enlarged side view of the elastic member 70shown in FIG. 4;

FIG. 8 is a graph showing the two-cycles of hysteresis curves of anelastomeric material, in a preferred embodiment;

FIG. 9 is a fragmentary enlarged perspective illustration of analternative embodiment of the elastomeric material; and

FIG. 10 is a plan view of one embodiment of the front ear panel 46.

DETAILED DESCRIPTION

All cited references are incorporated herein by reference in theirentireties. Citation of any reference is not an admission regarding anydetermination as to its availability as prior art to the claimedinvention.

Herein, “pull-on garment” refers to articles of wear which have adefined waist opening and a pair of leg openings and which are pulledonto the body of the wearer by inserting the legs into the leg openingsand pulling the article up over the waist. Herein, “disposable”describes garments which are not intended to be laundered or otherwiserestored or reused as a garment (i.e., they are intended to be discardedafter a single use and, preferably, to be recycled, composted orotherwise disposed of in an environmentally compatible manner). A“unitary” pull-on garment refers to pull-on garments which are formed ofseparate parts united together to form a coordinated entity, but the earpanels are not separate elements joined to a separate chassis; rather,the ear panels are formed by at least one layer which also forms thechassis of the garment (i.e., the garment does not require separatelymanipulative panels such as a separate chassis and separate ear panels).The pull-on garment is also preferably “absorbent” to absorb and containthe various exudates discharged from the body. A preferred embodiment ofthe pull-on garment of the present invention is the unitary disposableabsorbent pull-on garment, pull-on garment 120, shown in FIG. 1. Herein,“pull-on diaper” refers to pull-on garments generally worn by infantsand other incontinent individuals to absorb and contain urine and feces.It should be understood, however, that the present invention is alsoapplicable to other pull-on garments such as training pants, incontinentbriefs, feminine hygiene garments or panties, and the like. Herein,“panel” denotes an area or element of the pull-on garment. (While apanel is typically a distinct area or element, a panel may coincide(functionally correspond) somewhat with an adjacent panel.) Herein,“joined” or “joining” encompasses configurations whereby an element isdirectly secured to another by affixing the element directly to theother element, and configurations whereby the element is indirectlysecured to the other element by affixing the element to intermediatemember(s) which in turn are affixed to the other element. Herein,“uncontracted state” is used herein to describe states of pull-ongarments in its unseamed (i.e., seams are removed), flat and relaxedcondition wherein all elastic materials used are removed therefrom.

FIG. 1 shows one preferred embodiment of a disposable pull-on garment ofthe present invention (i.e., a unitary disposable pull-on diaper 120).Referring to FIG. 1, the disposable pull-on garment 120 of the presentinvention has a front region 26; a back region 28 and a crotch region 30between the front region 26 and the back region 28. A chassis 41 isprovided in the front, back and crotch regions 26, 28 and 30. Thechassis 41 includes a liquid pervious topsheet 24, a liquid imperviousbacksheet 22 associated with the topsheet 24, and an absorbent core 25(not shown in FIG. 1) disposed between the topsheet 24 and the backsheet22. The chassis 41 has side edges 220 which form edge lines 222 in thefront region 26.

The pull-on garment 120 of the invention further includes at least onepair of extensible ear panels 45 each extending laterally outward fromthe corresponding sides of the chassis 41. Each of the ear panels 45 hasan outermost edge 240 which forms an outermost edge line 242. At leastone of the outermost edge lines 242 has a nonuniform lateral distancefrom the longitudinal center line 100 (not shown in FIG. 1) in theuncontracted state of the garment 120.

In a preferred embodiment, the ear panels 45 continuously extend fromthe corresponding sides of the chassis 41 in the back region 28 to thecorresponding side edges 220 of the chassis 41 in the front region 26 asshown in FIG. 1. Alternatively, the ear panels 45 may continuouslyextend from the corresponding sides of the chassis 41 in the frontregion 26 to the corresponding side edges of the chassis 41 in the backregion 28 (not shown in FIG. 1).

The pull-on garment 120 of the invention has the ear panels 45 joined tothe chassis 41 to form two leg openings 34 and a waist opening 36.Preferably, the pull-on garment 120 further includes seams 232 eachjoining the chassis 41 and the ear panels 45 along the correspondingedge lines 222 and 242 to form the two leg openings 34 and the waistopening 36.

In a preferred embodiment, at least one of the ear panels 45 having,along the seam 232, a substantially bonded portion SB starting from thewaist opening 36 and an unbonded portion UB starting from the legopening 34. Preferably, the ratio in length of the unbonded portion tothe substantially bonded portion is between about 4:96 and 20:80.

FIG. 2 shows another preferred embodiment of a disposable pull-ongarment of the present invention (i.e., a unitary disposable pull-ondiaper 20). Referring to FIG. 2, the disposable pull-on garment 20includes a pair of extensible front ear panels 46 each extendinglaterally outward from the corresponding sides of the chassis 41 in thefront region 26, and a pair of extensible back ear panels 48 eachextending laterally outward from the corresponding sides of the chassis41 in the back region 28. Each of the ear panels 46 and 48 has anoutermost edge 240 which forms an outermost edge line 242. At least oneof the outermost edge lines 242 has a nonuniform lateral distance fromthe longitudinal center line 100 (not shown in FIG. 2 but in FIG. 3) inthe uncontracted state of the garment 20. The pull-on garment 20 furtherincludes seams 32 each joining the front and back ear panels 46 and 48along the corresponding edge lines 242 to form the two leg openings 34and the waist opening 36.

In a preferred embodiment, at least one of, more preferably both of, thepairs of the ear panels 45, 46 and 48 are elastically extensible in atleast the lateral direction. In alternative embodiments, the ear panels45, 46 and 48 are elastically extensible both in the lateral andlongitudinal directions. Herein, “extensible” refers to materials thatare capable of extending in at least one direction to a certain degreewithout undue rupture. Herein, “elasticity” and “elastically extensible”refer to extensible materials that have the ability to return toapproximately their original dimensions after the force that extendedthe material is removed. Herein, any material or element described as“extensible” may also be elastically extensible unless otherwiseprovided. The extensible ear panels 45, 46 and 48 provide a morecomfortable and contouring fit by initially conformably fitting thepull-on garment to the wearer and sustaining this fit throughout thetime of wear well past when the pull-on garment has been loaded withexudates since the ear panels 45, 46 and/or 48 allow the sides of thepull-on garment to expand and contract.

The ear panels 45, 46 and 48 may be formed by unitary elements of thepull-on garment 20 or 120 (i.e., they are not separately manipulativeelements secured to the pull-on garment 20 or 120, but rather are formedfrom and are extensions of one or more of the various layers of thepull-on garment). In a preferred embodiment, each of the ear panels 45,46 and 48 is a projected member of the chassis 41 (more clearly shown inFIG. 3). Preferably, the ear panels 45, 46 and 48 include at least oneunitary element or a continuous sheet material (e.g. the nonwoven outercover 74 in FIG. 4) that forms a part of the chassis 41 and continuouslyextends into the ear panels 45, 46 and 48. Alternatively, the ear panels45, 46 and 48 may be discrete members (shown in FIGS. 2, 2A, and 2Busing dashed lines) which do not have any unitary element that forms apart of the chassis 41, and may be formed by joining the discretemembers to the corresponding sides of the chassis 41.

In a preferred embodiment, the pull-on garment 20 or 120 furtherincludes seam panels 66 each extending laterally outward from each ofthe ear panels 45, 46 and 48; and tear open tabs 31 each extendinglaterally outward from the seam panel 66. In a preferred embodiment,each of the seam panels 66 is an extension of the corresponding earpanels 45, 46 and 48, or at least one of the component elements usedtherein, or any other combination of the elements. More preferably, eachof the tear open tabs 31 is also an extension of the corresponding seampanel 66 or at least one of its component elements used therein, or anyother combination of its elements.

The tear open tab 31 can take any shape as long as it facilitatesintentional tearing open at the seams 32 after soiling of the pull-ongarments 20 and 120. In a preferred embodiment, the lateral distance LDfrom the longitudinal center line 100 increases towards the leg opening34 as shown in FIG. 10. In this embodiment, the original material to beused for the front ear panel has a shape defined by the upper materialline 154 and the side material line 156 which is perpendicular to theupper material line 154. The outer most edge 240 and the tear open tab31 are formed by removing (or cutting out) the edge portions 158 fromthe original material. Since the tear open tab 31 can be obtained withinthe original material which has the right angle defined by the lines 154and 156, an effective material use can be achieved (i.e., the originalear panel material can be used effectively).

In a preferred embodiment, the corresponding edge portions of thechassis 41 and/or the ear panels 45, 46 and 48 are seamed directly orindirectly (e.g., through the seam panels 66), in an overlapping mannerto make an overlapped seam structure. Alternatively, the front and earpanels 46 and 48 can be seamed in a butt seam manner (shown in FIGS. 2Aand 2B). The bonding of the seams 32 can be performed by any suitablemeans known in the art appropriate for the specific materials employedin the chassis 41 and/or the ear panels 45, 46 and 48. Thus, sonicsealing, heat sealing, pressure bonding, adhesive or cohesive bonding,sewing, autogeneous bonding, and the like may be appropriate techniques.Preferably, the seam panels 66 are joined by a predetermined pattern ofheat/pressure or ultrasonic welds which withstands the forces andstresses generated on the garment 20 or 120 during wear.

A continuous belt 38 is formed by the ear panels 45, 46 and 48, and apart of the chassis 41 about the waist opening 36 as shown in FIGS. 1and 2. Preferably, elasticized waist bands 50 are provided in both thefront region 26 and the back region 28. The continuous belt 38 acts todynamically create fitment forces in the pull-on garment 20 or 120 whenpositioned on the wearer, to maintain the pull-on garment 20 or 120 onthe wearer even when loaded with body exudates thus keeping theabsorbent core 25 (not shown in FIG. 2) in close proximity to thewearer, and to distribute the forces dynamically generated during wearabout the waist thereby providing supplemental support for the absorbentcore 25 without binding or bunching the absorbent core 25.

FIG. 3 is a partially cut-away plan view of the pull-on garment 20 ofFIG. 2 in its uncontracted state (except in the ear panels 46 and 48which are left in their relaxed condition) with the topsheet 24 facingthe viewer, prior to the ear panels 46 and 48 being joined together bythe seams 32. The pull-on garment 20 has the front region 26, the backregion 28 opposed to the front region 26, the crotch region 30positioned between the front region 26 and the back region 28, and aperiphery which is defined by the outer perimeter or edges of thepull-on garment 20 in which the side edges are designated 150 and 240,and the end edges or waist edges are designated 152. The topsheet 24 hasthe body-facing surface of the pull-on garment 20 which is positionedadjacent to the wearer's body during use. The backsheet 22 has theouter-facing surface of the pull-on garment 20 which is positioned awayfrom the wearer's body. The pull-on garment 20 includes the chassis 41including the liquid pervious topsheet 24, the liquid imperviousbacksheet 22 associated with the topsheet 24, and the absorbent core 25positioned between the topsheet 24 and the backsheet 22. The garment 20further includes the front and back ear panels 46 and 48 extendinglaterally outward from the chassis 41, the elasticized leg cuffs 52, andthe elasticized waistbands 50. The topsheet 24 and the backsheet 22 havelength and width dimensions generally larger than those of the absorbentcore 25. The topsheet 24 and the backsheet 22 extend beyond the edges ofthe absorbent core 25 to thereby form the side edges 150 and the waistedges 152 of the garment 20. The liquid impervious backsheet 22preferably includes a liquid impervious plastic film 68.

The pull-on garment 20 also has two centerlines, a longitudinalcenterline 100 and a transverse centerline 110. Herein, “longitudinal”refers to a line, axis, or direction in the plane of the pull-on garment20 that is generally aligned with (e.g. approximately parallel with) avertical plane which bisects a standing wearer into left and righthalves when the pull-on garment 20 is worn. Herein, “transverse” and“lateral” are interchangeable and refer to a line, axis or directionwhich lies within the plane of the pull-on garment that is generallyperpendicular to the longitudinal direction (which divides the wearerinto front and back body halves). The pull-on garment 20 and componentmaterials thereof also have a body-facing surface which faces the skinof wearer in use and an outer-facing surface which is the oppositesurface to the body-facing surface.

Each of the ear panels 45, 46 and 48 of the present invention has theoutermost edge line 242. Herein, “edge line” refers to lines whichdefine the outlines of the ear panels 45, 46 and 48 or the chassis 41.Herein, “outermost” refers to portions which are farthest from thelongitudinal centerline 100. At least one of the edge lines 242 has anonuniform lateral distance LD from the longitudinal center line 100 inthe uncontracted state of the garment 20.

In a preferred embodiment, the outermost edge line 242 has a first point251 at the closest portion to the waist opening 36 and a second point252 at the closest portion to the leg opening 34, and the outermost edgeline 242 is a straight line defined by connecting the first and secondpoints 251 and 252. The outermost edge line 242 shows the direction ofthe outermost edge 240 of the ear panel. In a preferred embodiment, theedge line 242 leans to the longitudinal center line 100 in theuncontracted state of the pull-on garment 20. More preferably, theoutermost edge line 242 has, in the uncontracted state of the pull-ongarment 20, a lateral distance LD from the longitudinal center line 100which increases towards the leg opening 34 as shown in FIG. 3.Alternatively, the outermost edge line 242 may have, in the uncontractedstate of the pull-on garment 20, a lateral distance LD from thelongitudinal center line 100 which decreases towards the leg opening 34(not shown in Figs.).

While the topsheet 24, the backsheet 22, and the absorbent core 25 maybe assembled in a variety of well known configurations, exemplarychassis configurations are described generally in U.S. Pat. No.3,860,003 entitled “Contractible Side Portions for Disposable Diaper”which issued to Kenneth B. Buell on Jan. 14, 1975; and U.S. Pat. No.5,151,092 entitled “Absorbent Article With Dynamic Elastic Waist FeatureHaving A Predisposed Resilient Flexural Hinge” which issued to KennethB. Buell et al., on Sep. 29, 1992.

FIG. 4 is a cross-sectional view of a preferred embodiment taken alongthe section line 4-4 of FIG. 3. The pull-on garment 20 includes thechassis 41 including the liquid pervious topsheet 24, the liquidimpervious backsheet 22 associated with the topsheet 24, and theabsorbent core 25 positioned between the topsheet 24 and the backsheet22. The pull-on garment further includes the front ear panels 46 eachextending laterally outward from the chassis 41, and an inner barriercuffs 54. Although FIG. 4 depicts only the structure of the front earpanel 46 and the chassis 41 in the front region 26, preferably a similarstructure is also provided in the back region 28. In a preferredembodiment, each of the front ear panels 46 is formed by a lamination ofan extended part 72 of the barrier flap 56, an elastic member 70 and thenonwoven outer cover 74. The elastic member 70 includes a planeelastomeric material 124 (not shown in FIG. 4 but in FIG. 6). Herein,“plane elastomeric material” refers to elastomeric materials whichcontinuously extend in two dimensional directions. Preferred planeelastomeric materials include a scrim, a perforated (or aperturesformed) film, an elastomeric woven or nonwoven, and the like. In apreferred embodiment, the plane elastomeric material 124 includes atleast a portion that has a nonuniform lateral width.

FIG. 5 is a more detailed plan view of the front and back ear panels 46and 48 shown in FIG. 2. In FIG. 5, the nonwoven outer cover 74 isremoved from the ear panels 46 and 48 to clearly show the elasticmembers 70 and the seam 32. In a preferred embodiment, each of the earpanels 46 and 48 includes the elastic member 70 which includes a planeelastomeric material 124 (such as the one shown in FIG. 6). The elasticmember 70 may further include an extensible sheet or film material(e.g., a nonwoven material) which is joined to the plane elastomericmaterial 124.

In a preferred embodiment, the plane elastomeric material 124 has anidentical shape and dimensions with the elastic member 70. The elasticmember 70 and the plane elastomeric material 124 may take a wide varietyof sizes and shapes (e.g., triangular, rectangular, other quadrilateral,and other polygon). In a preferred embodiment, the plane elastomericmaterial 124 has at least a portion that has a nonuniform lateral widthLW. Preferably, the lateral width LW of the plane elastomeric material124 increases towards the leg opening 34 as shown in FIG. 5.Alternatively, the lateral width LW of the plane elastomeric material124 may decrease towards the leg opening 34 (not shown in Figs.).

In a preferred embodiment, the seam 32 is formed on a seaming line 230which is preliminary determined along the edge lines 242. The seamingline 230 can be determined from any straight lines which may be drawn inthe overlapped area 238 between the edge lines 242. More preferably, theseaming line 230 is formed along, more preferably in parallel with, thecorresponding edge lines 242. In a more preferred embodiment, a straightline which equally divides the overlapped area 238 is chosen as theseaming line 230 as shown in FIG. 5.

In a preferred embodiment, the seaming line 230 leans to thelongitudinal center line 100 in the uncontracted state of the garment20. Preferably, the lateral distance of the seaming line 230 from thelongitudinal center line 100 increases toward the leg opening 34.Alternatively, the lateral distance of the seaming line 230 from thelongitudinal center line 100 decreases toward the leg opening 34 (notshown in Figs.).

A preferred seam 32 is formed by a plurality of discrete spaced apartseaming bonds 236 which are formed on the seaming line 230 as shown inFIG. 5. The discrete seaming bonds 236 form, on the seaming line 230, asubstantially bonded portion SB starting from the waist opening 36 andan unbonded portion UB starting from the leg opening 34. Herein,“substantially bonded portion” refers to portions which areintermittently and/or continuously joined to other materials tocontribute to the formation of the leg and waist openings 34 and 36.Herein, “unbonded portion” refers to portions which are not joined toother materials.

In an alternative embodiment, the seam 32 may be formed by a continuousbond which continuously bonds the front and back ear panels 46 and 48 onthe seaming line 230 (not shown in Figs.). The continuous bond alsoforms, on the seaming line 230, a substantially bonded portion SBstarting from the waist opening 36 and an unbonded portion UB startingfrom the leg opening 34.

To avoid a red marking problem on wearer's skin, the preferred ratio inlength of the unbonded portion UB to the substantially bonded portion SBis from about 4:96 to about 20:80, more preferably from about 8:92 toabout 15:85, yet more preferably from about 10:90 to about 13:87.Preferred disposable pull-on garments for infants have an unbondedportion UB from the leg opening 34, in length, from about 4 mm to about20 mm, more preferably from about 8 mm to about 15 mm, yet morepreferably from about 10 mm to about 13 mm.

In a preferred embodiment, at least one of the ear panels 45, 46 and 48is partially shaped to form a tear open tab 231 associated with theunbonded portion UB for an easy tear open after soiling. The tear opentab 231 can take any shape as long as it facilitates intentional tearingopen at the seams 32. In this embodiment, the ear panels 45, 46 and 48can be torn open from the leg opening 34 after soiling. Thus, theoriginal tear open tab 31 can be eliminated in this embodiment.

The method for making a disposable pull-on garment 20 or 120 of thepresent invention includes the step of preparing the chassis 41 providedin the front, back and crotch regions 26, 28, and 30 and having edgelines 222 in the front and back regions 26 and 28. The method furtherincludes the step of joining each of the ear panels 45, 46 and 48 to thechassis 41 along the corresponding edge lines 222 and 242 to form a seam32 and 232, thereby forming two leg openings 34 and a waist opening 36,so that at least one of the ear panels 45, 46 and 48 has, along the seam32, the substantially bonded portion SB starting from the waist opening36 and the unbonded portion UB starting from the leg opening 34. Theratio in length of the unbonded portion UB to the substantially bondedportion SB is between about 4:96 and about 20:80.

The absorbent core 25 can be any absorbent member which is generallycompressible, conformable, non-irritating to the wearer's skin, andcapable of absorbing and retaining liquids such as urine and othercertain body exudates. The absorbent core 25 may be manufactured in awide variety of sizes and shapes (e.g., rectangular, hourglass,“T”-shaped, asymmetric, etc.) and from a wide variety ofliquid-absorbent materials commonly used in disposable pull-on garmentsand other absorbent articles such as comminuted wood pulp which isgenerally referred to as airfelt. Examples of other suitable absorbentmaterials include creped cellulose wadding; meltblown polymers includingcoform; chemically stiffened, modified or cross-linked cellulosicfibers; tissue including tissue wraps and tissue laminates; absorbentfoams; absorbent sponges; superabsorbent polymers; absorbent gellingmaterials; or any equivalent material or combinations of materials.

In a preferred embodiment of the invention, the absorbent core 25 has,in the uncontracted state of the pull-on garment 20, an area ratio ofthe core area to the garment area of greater than about 25%, morepreferably greater than about 40%. The core area is defined as the totalarea of the body-facing surface of the absorbent core 25 in theuncontracted state of the pull-on garment 20. The periphery of thebody-facing surface of the absorbent core 25 is determined by theoutline of aggregates of primary absorbent materials used in theabsorbent core 25. Herein, “primary absorbent material” refers toabsorbent materials which occupy more than about 80% in dry state volumeof the absorbent core 25. In a preferred embodiment, a wood pulp (e.g.,airfelt) is considered a primary absorbent material of the absorbentcore 25 and defines the periphery of the body-facing surface of theabsorbent core 25, thus defining the core area of the absorbent core 25.The other primary absorbent materials may include creped cellulosewadding; meltblown polymers including coform; chemically stiffened,modified or cross-linked cellulosic fibers; tissue including tissuewraps and tissue laminates; absorbent foams; absorbent sponges;superabsorbent polymers; absorbent gelling materials; or any equivalentmaterial or combinations of materials.

The garment area is defined as the total area of the body-facing surfaceof the pull-on garment 20 in the uncontracted state. Therefore, the arearatio is calculated as follows:

AR=CA/GA×100

wherein,

-   AR: the area ratio (%)-   CA: the core area (cm²)-   GA: the total area (cm²)

In a preferred embodiment for infant use, the absorbent core 25 has acore area of less than about 450 cm², more preferably less than about425 cm². Preferably, the absorbent core 25 has a maximum core width ofless than about 12 cm, more preferably less than about 11 cm. Herein,“core width” refers to the lateral distance from one side edge to theother side edge of the absorbent core 25.

The configuration and construction of the absorbent core 25 may vary(e.g., the absorbent core 25 may have varying caliper zones, ahydrophilic gradient, a superabsorbent gradient, or lower averagedensity and lower average basis weight acquisition zones; or may includeone or more layers or structures). Further, the size and absorbentcapacity of the absorbent core 25 may also be varied to accommodatewearers ranging from infants through adults. However, the totalabsorbent capacity of the absorbent core 25 should be compatible withthe design loading and the intended use of the garment 20.

A preferred embodiment of the garment 20 has an asymmetric, modifiedhourglass-shaped absorbent core 25 having ears in the front and backwaist regions 26 and 28. Other exemplary absorbent structures for use asthe absorbent core 25 that have achieved wide acceptance and commercialsuccess are described in U.S. Pat. No. 4,610,678 entitled “High-DensityAbsorbent Structures” issued to Weisman et al. on Sep. 9, 1986; U.S.Pat. No. 4,673,402 entitled “Absorbent Articles With Dual-Layered Cores”issued to Weisman et al. on Jun. 16, 1987; U.S. Pat. No. 4,888,231entitled “Absorbent Core Having A Dusting Layer” issued to Angstadt onDec. 19, 1989; and U.S. Pat. No. 4,834,735, entitled “High DensityAbsorbent Members Having Lower Density and Lower Basis WeightAcquisition Zones”, issued to Alemany et al. on May 30, 1989.

The chassis 41 may further include an acquisition/distribution core 84of chemically stiffened fibers positioned over the absorbent core 25,thereby forming a dual core system. In a preferred embodiment, thefibers are hydrophilic chemically stiffened cellulosic fibers. Herein,“chemically stiffened fibers” means any fibers which have been stiffenedby chemical means to increase stiffness of the fibers under both dry andaqueous conditions. Such means include the addition of chemicalstiffening agents which, for example, coat and/or impregnate the fibers.Such means also include the stiffening of the fibers by altering thechemical structure of the fibers themselves, e.g., by cross-linkingpolymer chains.

The fibers utilized in the acquisition/distribution core 84 can also bestiffened by means of chemical reaction. For example, crosslinkingagents can be applied to the fibers which, subsequent to application,are caused to chemically form intrafiber crosslink bonds. Thesecrosslink bonds can increase stiffness of the fibers. Whereas theutilization of intrafiber crosslink bonds to chemically stiffen thefibers is preferred, it is not meant to exclude other types of reactionsfor chemical stiffening of the fibers.

In the more preferred stiffened fibers, chemical processing includesintrafiber crosslinking with crosslinking agents while such fibers arein a relatively dehydrated, defibrated (i.e. individualized), twisted,curled condition. Suitable chemical stiffening agents include monomericcrosslinking agents including, but not limited to, C₂-C₈ dialdehydes andC₂-C₈ monoaldehydes having an acid functionality can be employed to formthe cross linking solution. These compounds are capable of reacting withat least two hydroxyl groups in a single cellulose chain or onproximately located cellulose chains in a single fiber. Suchcrosslinking agents contemplated for use in preparing the stiffenedcellulose fibers include, but are not limited to, glutaraldehyde,glyoxal, formaldehyde, and glyoxylic acid. Other suitable stiffeningagents are polycarboxylates, such as citric acid. The polycarboxylicstiffening agents and a process for making stiffened fibers from themare described in U.S. Pat. No. 5,190,563, entitled “Process forPreparing Individualized, Polycarboxylic Acid crosslinked Fibers” issuedto Herron, on Mar. 2, 1993. The effect of crosslinking under theseconditions is to form fibers which are stiffened and which tend toretain their twisted, curled configuration during use in the absorbentarticles herein. Such fibers, and processes for making them are cited inthe above incorporated patents.

Preferred dual core systems are disclosed in U.S. Pat. No. 5,234,423,entitled “Absorbent Article With Elastic Waist Feature and EnhancedAbsorbency” issued to Alemany et al., on Aug. 10, 1993; and in U.S. Pat.No. 5,147,345, entitled “High Efficiency Absorbent Articles ForIncontinence Management” issued to Young, LaVon and Taylor on Sep. 15,1992. In a preferred embodiment, the acquisition/distribution core 84includes chemically treated stiffened cellulosic fiber material,available from Weyerhaeuser Co. (U.S.A.) under the trade designation of“CMC”. Preferably, the acquisition/distribution core 84 has a basisweight of from about 40 g/m² to about 400 g/m², more preferably fromabout 75 g/m² to about 300 g/m².

More preferably, the chassis 22 further includes anacquisition/distribution layer 82 between the topsheet 24 and theacquisition/distribution core 84 as shown in FIG. 4. Theacquisition/distribution layer 82 is provided to help reduce thetendency for surface wetness of the topsheet 24. Theacquisition/distribution layer 82 preferably includes carded, resinbonded hiloft nonwoven materials such as, for example, available as CodeNo. FT-6860 from Polymer Group, Inc., North America (Landisiville, N.J.,U.S.A.), which is made of polyethylene telephthalate fibers of 6 dtex,and has a basis weight of about 43 g/m². A preferable example for theacquisition/distribution layer 82 and the acquisition/distribution core84 is disclosed in EP 0797968A1 (Kurt et al.) published on Oct. 1, 1997.

The topsheet 24 is preferably compliant, soft feeling, andnon-irritating to the wearer's skin. Further, the topsheet 24 is liquidpervious permitting liquids (e.g., urine) to readily penetrate throughits thickness. A suitable topsheet 24 may be manufactured from a widerange of materials such as woven and nonwoven materials; polymericmaterials such as apertured formed thermoplastic films, aperturedplastic films, and hydroformed thermoplastic films; porous foams;reticulated foams; reticulated thermoplastic films; and thermoplasticscrims. Suitable woven and nonwoven materials can be included of naturalfibers (e.g., wood or cotton fibers), synthetic fibers (e.g., polymericfibers such as polyester, polypropylene, or polyethylene fibers) or froma combination of natural and synthetic fibers. The topsheet 24 ispreferably made of a hydrophobic material to isolate the wearer's skinfrom liquids which have passed through the topsheet 24 and are containedin the absorbent core 25 (i.e., to prevent rewet). If the topsheet 24 ismade of a hydrophobic material, at least the upper surface of thetopsheet 24 is treated to be hydrophilic so that liquids will transferthrough the topsheet more rapidly. This diminishes the likelihood thatbody exudates will flow off the topsheet 24 rather than being drawnthrough the topsheet 24 and being absorbed by the absorbent core 25. Thetopsheet 24 can be rendered hydrophilic by treating it with asurfactant. Suitable methods for treating the topsheet 24 with asurfactant include spraying the topsheet 24 material with the surfactantand immersing the material into the surfactant. A more detaileddiscussion of such a treatment and hydrophilicity is contained in U.S.Pat. No. 4,988,344 entitled “Absorbent Articles with Multiple LayerAbsorbent Layers” issued to Reising, et al. on Jan. 29, 1991 and U.S.Pat. No. 4,988,345 entitled “Absorbent Articles with Rapid AcquiringAbsorbent Cores” issued to Reising on Jan. 29, 1991.

In a preferred embodiment, the topsheet 24 is a nonwoven web that canprovide reduced tendency for surface wetness; and consequentlyfacilitate maintaining urine absorbed by the core 25 away from theuser's skin, after wetting. One of the preferred topsheet materials is athermobonded carded web which is available as Code No. P-8 from FiberwebNorth America, Inc. (Simpsonville, S.C., U.S.A.). Another preferredtopsheet material is available as Code No. S-2355 from Havix Co., Japan.This material is a bi-layer composite material, and made of two kinds ofsynthetic surfactant treated bicomponent fibers by using carding andair-through technologies. Yet another preferred topsheet material is athermobonded carded web which is available as Code No. Profleece Style040018007 from Amoco Fabrics, Inc. (Gronau, Germany).

In a preferred embodiment, the topsheet 24 is compatible with othermaterials (e.g., component materials in the backsheet 22) used in thepull-on garment 20 or 120, in terms of its design/process, for formingventilation holes along the waist edge 152 and/or at other portions ofthe pull-on garment 20 or 120.

Another preferred topsheet 24 includes an apertured formed film.Apertured formed films are preferred for the topsheet 24 because theyare pervious to body exudates and yet non-absorbent and have a reducedtendency to allow liquids to pass back through and rewet the wearer'sskin. Thus, the surface of the formed film which is in contact with thebody remains dry, thereby reducing body soiling and creating a morecomfortable feel for the wearer. Suitable formed films are described inU.S. Pat. No. 3,929,135, entitled “Absorptive Structures Having TaperedCapillaries”, issued to Thompson on Dec. 30, 1975; U.S. Pat. No.4,324,246 entitled “Disposable Absorbent Article Having A StainResistant Topsheet”, issued to Mullane, et al. on Apr. 13, 1982; U.S.Pat. No. 4,342,314 entitled “Resilient Plastic Web Exhibiting Fiber-LikeProperties”, issued to Radel. et al. on Aug. 3, 1982; U.S. Pat. No.4,463,045 entitled “Macroscopically Expanded Three-Dimensional PlasticWeb Exhibiting Non-Glossy Visible Surface and Cloth-Like TactileImpression”, issued to Ahr et al. on Jul. 31, 1984; and U.S. Pat. No.5,006,394 “Multilayer Polymeric Film” issued to Baird on Apr. 9, 1991.

In a preferred embodiment, the backsheet 22 includes the liquidimpervious film 68 as shown in, for example, FIG. 4. Preferably, theliquid impervious film 68 longitudinally extends in the front, back andcrotch regions 26, 28 and 30. More preferably, the liquid imperviousfilm 68 does not laterally extend into the at least one of the earpanels 46 or 48. The liquid impervious film 68 has a body-facing surface79 and an outer-facing surface 77. The liquid impervious film 68 isimpervious to liquids (e.g., urine) and is preferably manufactured froma thin plastic film. However, more preferably the plastic film permitsvapors to escape from the garment 20. In a preferred embodiment, amicroporous polyethylene film is used for the liquid impervious film 68.A suitable microporous polyethylene film is manufactured by MitsuiToatsu Chemicals, Inc., Nagoya, Japan and marketed in the trade as PG-P.In a preferred embodiment, a disposable tape (not shown in Figs.) isadditionally joined to the outer surface of the backsheet 22 to providea convenient disposal after soiling.

A suitable material for the liquid impervious film 68 is a thermoplasticfilm having a thickness of from about 0.012 mm (0.5 mil) to about 0.051mm (2.0 mils), preferably including polyethylene or polypropylene.Preferably, the liquid impervious film has a basis weight of from about5 g/m² to about 35 g/m². However, it should be noted that other flexibleliquid impervious materials may be used. Herein, “flexible” refers tomaterials which are compliant and which will readily conform to thegeneral shape and contours of the wearer's body.

Preferably, the backsheet 22 further includes the nonwoven outer cover74 which is joined with the outer-facing surface of the liquidimpervious film 68 to form a laminate (i.e., the backsheet 22). Thenonwoven outer cover 74 is positioned at the outermost portion of thegarment 20 and covers at least a portion of the outermost portion of thegarment 20. In a preferred embodiment, the nonwoven outer cover 74covers almost all of the area of the outermost portion of the garment20. The nonwoven outer cover 74 may be joined to the liquid imperviousfilm 68 by any suitable attachment means known in the art. For example,the nonwoven outer cover 74 may be secured to the liquid impervious film68 by a uniform continuous layer of adhesive, a patterned layer ofadhesive, or an array of separate lines, spirals, or spots of adhesive.Suitable adhesives include a hotmelt adhesive obtainable from NittaFindley Co., Ltd., Osaka, Japan as H-2128, and a hotmelt adhesiveobtainable from H.B. Fuller Japan Co., Ltd., Osaka, Japan as JM-6064.

In a preferred embodiment, the nonwoven outer cover 74 is a cardednonwoven web, for example, obtainable from Havix Co., LTD., Gifu, Japanas E-2341. The nonwoven outer cover 74 is made of bi-component fibers ofa polyethylene (PE) and a polypropylene (PP). The ratio of PE/PP isabout 50/50. The PE/PP bi-component fiber has the dimension of 2 d×51mm. Another preferred carded nonwoven web is obtainable from ChissoCorp., Moriyama, Japan. The nonwoven outer cover 74 is also made ofbi-component fibers of a polyethylene (PE) and a polypropylene (PP). Theratio of PE/PP is about 50/50.

In another preferred embodiment, the nonwoven web is a spunbondednonwoven web, for example, obtainable from Mitsui PetrochemicalIndustries, Ltd., Tokyo, Japan. The nonwoven web is made of bi-componentfibers of a polyethylene (PE) and a polypropylene (PP). The ratio ofPE/PP is about 80/20. The PE/PP bi-component fiber has the thickness isapproximately 2.3 d.

In a preferred embodiment, the backsheet 22 is compatible with othermaterials (e.g., component materials in the topsheet 24) used in thepull-on garment 20 or 120, in terms of its design/process, for formingventilation holes along the waist edge 152 and/or for forming seams 32in the pull-on garment 20 or 120.

The backsheet 22 is preferably positioned adjacent the outer-facingsurface of the absorbent core 25 and is preferably joined thereto by anysuitable attachment means known in the art. For example, the backsheet22 may be secured to the absorbent core 25 by a uniform continuous layerof adhesive, a patterned layer of adhesive, or an array of separatelines, spirals, or spots of adhesive. Adhesives which have been found tobe satisfactory are manufactured by H. B. Fuller Company of St. Paul,Minn., U.S.A., and marketed as HL-1358J. An example of a suitableattachment means including an open pattern network of filaments ofadhesive is disclosed in U.S. Pat. No. 4,573,986 entitled “DisposableWaste-Containment Garment”, which issued to Minetola et al. on Mar. 4,1986. Another suitable attachment means including several lines ofadhesive filaments swirled into a spiral pattern is illustrated by theapparatus and methods shown in U.S. Pat. No. 3,911,173 issued toSprague, Jr. on Oct. 7, 1975; U.S. Pat. No. 4,785,996 issued to Ziecker,et al. on Nov. 22, 1978; and U.S. Pat. No. 4,842,666 issued to Wereniczon Jun. 27, 1989. Alternatively, the attachment means may include heatbonds, pressure bonds, ultrasonic bonds, dynamic mechanical bonds, orany other suitable attachment means or combinations of these attachmentmeans as are known in the art.

In an alternative embodiment, the absorbent core 25 is not joined to thebacksheet 22, and/or the topsheet 24 in order to provide greaterextensibility in the front region 26 and the back region 28.

The pull-on garment 20 preferably further includes elasticized leg cuffs52 for providing improved containment of liquids and other bodyexudates. The elasticized leg cuffs 52 may include several differentembodiments for reducing the leakage of body exudates in the legregions. (The leg cuffs can be and are sometimes also referred to as legbands, side flaps, barrier cuffs, elastic cuffs or gasketing cuffs.)U.S. Pat. No. 3,860,003 entitled “Contractable Side Portions forDisposable Diaper” issued to Buell on Jan. 14, 1975, describes adisposable diaper which provides a contractible leg opening having aside flap and one or more elastic members to provide an elasticized legcuff. U.S. Pat. No. 4,909,803 entitled “Disposable Absorbent ArticleHaving Elasticized Flaps” issued to Aziz et al. on Mar. 20, 1990,describes a disposable diaper having “stand-up” elasticized flaps(barrier cuffs) to improve the containment of the leg regions. U.S. Pat.No. 4,695,278 entitled “Absorbent Article Having Dual Cuffs” issued toLawson on Sep. 22, 1987; and U.S. Pat. No. 4,795,454 entitled “AbsorbentArticle Having Leakage-Resistant Dual Cuffs” issued to Dragoo on Jan. 3,1989, describe disposable diapers having dual cuffs including agasketing cuff and a barrier cuff. U.S. Pat. 4,704,115 entitled“Disposable Waist Containment Garment” issued to Buell on Nov. 3, 1987,discloses a disposable diaper or incontinence garment havingside-edge-leakage-guard gutters configured to contain free liquidswithin the garment.

While each elasticized leg cuff 52 may be configured so as to be similarto any of the leg bands, side flaps, barrier cuffs, or elastic cuffsdescribed above, it is preferred that the elasticized leg cuff 52includes an elastic gasketing cuff 62 with one or more elastic strands64 as shown in FIG. 3, which is described in the above-referred U.S.Pat. Nos. 4,695,278 and 4,795,454. It is also preferred that eachelasticized leg cuff 52 further includes inner barrier cuffs 54 eachincluding a barrier flap 56 and a spacing means 58 which are describedin the above-referenced U.S. Pat. No. 4,909,803.

The pull-on garment 20 preferably further includes an elasticizedwaistband 50 that provides improved fit and containment. The elasticizedwaistband 50 is that portion or zone of the pull-on garment 20 which isintended to elastically expand and contract to dynamically fit thewearer's waist. The elasticized waistband 50 preferably extendslongitudinally outwardly from the waist edge of the pull-on garment 20toward the waist edge of the absorbent core 25. Preferably, the pull-ongarment 20 has two elasticized waistbands 50, one positioned in the backregion 28 and one positioned in the front region 26, although otherpull-on diaper embodiments can be constructed with a single elasticizedwaistband. The elasticized waistband 50 may be constructed in a numberof different configurations including those described in U.S. Pat. No.4,515,595 entitled “Disposable Diapers with Elastically ContractibleWaistbands” issued to Kievit et al. on May 7, 1985 and the abovereferenced U.S. Pat. No. 5,151,092 issued to Buell.

The waistbands 50 may include materials that have been “prestrained” or“mechanically prestrained” (i.e., subjected to some degree of localizedpattern mechanical stretching to permanently elongate the material). Thematerials may be prestrained using deep embossing techniques as areknown in the art. Alternatively, the materials may be prestrained bydirecting the material through an incremental mechanical stretchingsystem as described in U.S. Pat. No. 5,330,458 entitled “AbsorbentArticle With Elastic Feature Having A Portion Mechanically Prestrained”issued to Buell et al., on Jul. 19, 1994. The materials are then allowedto return to their substantially untensioned condition, thus forming azero strain stretch material that is extensible, at least up to thepoint of initial stretching. Examples of zero strain materials aredisclosed in U.S. Pat. No. 2,075,189 issued to Galligan on Mar. 30,1937; U.S. Pat. No. 3,025,199 issued to Harwood on Mar. 13, 1962; U.S.Pat. Nos. 4,107,364 and 4,209,563 issued to Sisson on Aug. 15, 1978 andJun. 24, 1980, respectively; U.S. Pat. No. 4,834,741 issued to Sabee onMay 30, 1989; and U.S. Pat. No. 5,151,092 issued to Buell et al., onSep. 29, 1992.

At least one of the ear panels 45, 46 and 48 includes the elastic member70 as shown in FIG. 4. The elastic member 70 of the front ear panels 46includes the elastomeric material 124 (not shown in FIG. 4) whichpreferably extends laterally outward from the chassis 41 to provide goodfitness by generating the optimal retention (or sustained) force at thewaist and side areas of the wearer. Preferably, the elastomeric material124 is extensible in at least one direction, preferably in the lateraldirection to generate a retention (or sustained) force that is optimalto prevent the pull-on garment 20 from drooping, sagging, or slidingdown from its position on the torso without causing the red marking onthe skin of the wearer. In a preferred embodiment, each of the earpanels 45, 46 and 48 includes the elastomeric material 124.

The elastic member 70 is operatively joined to at least one of thenonwoven webs 72 and 74 in the ear panels 45, 46 and 48 to allow theelastic member 70 to be elastically extensible in at least the lateraldirection. In a preferred embodiment, the elastic member 70 isoperatively joined to the nonwoven webs 72 and 74 by securing them to atleast one, preferably both of the nonwoven webs 72 and 74 while in asubstantially untensioned (zero strain) condition.

The elastic member 70 can be operatively joined to the nonwoven webs 72and 74, by using either an intermittent bonding configuration or asubstantially continuous bonding configuration. Herein, “intermittently”bonded laminate web means a laminate web wherein the plies are initiallybonded to one another at discrete spaced apart points or a laminate webwherein the plies are substantially unbonded to one another at discretespaced apart areas. Conversely, a “substantially continuously” bondedlaminate web means a laminate web wherein the plies are initially bondedsubstantially continuously to one another throughout the areas ofinterface. It is preferred that the stretch laminate be bonded over allor a significant portion of the stretch laminate so that the inelasticwebs (i.e., the nonwoven webs 72 and 74) elongate or draw withoutcausing rupture, and the layers of the stretch laminates are preferablybonded in a configuration that maintains all of the layers of thestretch laminate in relatively close adherence to one another after theincremental mechanical stretching operation. Consequently, the elasticpanel members and the other plies of the stretch laminate are preferablysubstantially continuously bonded together using an adhesive. In aparticularly preferred embodiment, the adhesive selected is applied witha control coat spray pattern at a basis weight of about 7.0 grams/squarem. The adhesive pattern width is about 6.0 cm. The adhesive ispreferably an adhesive such as is available from Nitta Findley Co.,Ltd., Osaka, Japan, under the designation H2085F. Alternatively, theelastic panel member and any other components of the stretch laminatesmay be intermittently or continuously bonded to one another using heatbonding, pressure bonding, ultrasonic bonding, dynamic mechanicalbonding, or any other method as is known in the art.

After the elastic member 70 is operatively joined to at least one of thenonwoven webs 72 and 74, at least a portion of the resultant compositestretch laminate is then subjected to mechanical stretching sufficientto permanently elongate the non-elastic components which are, forexample, the nonwoven webs 72 and 74. The composite stretch laminate isthen allowed to return to its substantially untensioned condition. Atleast one pair of, preferably both of the ear panels 45, 46 and 48 isthus formed into “zero strain” stretch laminates. (Alternatively, theelastic member 70 could be operatively joined in a tensioned conditionand then subjected to mechanical stretching; although this is not aspreferred as a “zero strain” stretch laminate.) Herein, “zero strain”stretch laminate refers to a laminate included of at least two plies ofmaterial which are secured to one another along at least a portion oftheir coextensive surfaces while in a substantially untensioned (“zerostrain”) condition; one of the plies including a material which isstretchable and elastomeric (i.e., will return substantially to itsuntensioned dimensions after an applied tensile force has been released)and a second ply which is elongatable (but not necessarily elastomeric)so that upon stretching the second ply will be, at least to a degree,permanently elongated so that upon release of the applied tensileforces, it will not fully return to its original undeformedconfiguration. The resulting stretch laminate is thereby renderedelastically extensible, at least up to the point of initial stretching,in the direction of initial stretching. Particularly preferred methodsand apparatus used for making stretch laminates utilize meshingcorrugated rolls to mechanically stretch the components. Particularlypreferred apparatus and methods are disclosed in U.S. Pat. No. 5,167,897issued to Weber et al. on Dec. 1, 1992; U.S. Pat. No. 5,156,793 issuedto Buell et al. on Oct. 20, 1990; and U.S. Pat. No. 5,143,679 issued toWeber et al. on Sep. 1, 1992.

The elastic member 70 is preferably joined to, more preferably directlysecured to the respective edges 78 of the liquid impervious film (i.e.,the liquid impervious film 68) through an adhesive 76 as shown in FIG.4. In a preferred embodiment, while liquid impervious film 68longitudinally extends in the front, back and crotch regions 26, 28 and30, it does not laterally extend into at least one of, preferably eachof the extensible ear panels 45, 46 and 48. In a more preferredembodiment, the elastic member 70 is joined to the respective edges 78of the liquid impervious film 68 at the outer-facing surface 77 as shownin FIG. 4. In an alternative embodiment, the elastic member 70 may bejoined to the respective edges 78 of the liquid impervious film 68 atthe body-facing surface 79 (not shown in Figs.). Preferably, theadhesive 76 is applied in a spiral glue pattern. In a preferredembodiment, the adhesive 76 is a flexible adhesive with an amorphous andcrystallizing component. Such a preferred adhesive is made by NittaFindley Co., Ltd., Osaka, Japan, under the designation H2085F.Alternatively, the elastic member 70 may be joined to the respectiveedges 78 of the liquid impervious film 68 by any other bonding meansknown in the art which include heat bonds, pressure bonds, ultrasonicbonds, dynamic mechanical bonds, or combinations of these attachmentmeans.

Referring to FIG. 6, the elastic member 70 includes the elastomericmaterial 124 having a first surface 150 and a second surface 152opposing the first surface 150, and a first coverstock layer 122 whichis joined to the first surface 150 of the elastomeric material 124. In apreferred embodiment, the first coverstock layer 122 is joined to thefirst surface 150 of the elastomeric material 124 by an adhesive 160 asshown, for example, in FIG. 7. More preferably, the elastic member 70further includes a second coverstock layer 126 which is joined to thesecond surface 152 of the elastomeric material 124 by an adhesive 164.

Preferably, the elastic member 70 is joined to the respective edges 78of the liquid impervious film 68 at the outer-facing surface 77 as shownin FIG. 4. In an alternative embodiment, the elastic member 70 may bejoined to the respective edges 78 of the liquid impervious film 68 atthe body-facing surface 79 (not shown in Figs.).

The elastomeric material 124 may be formed in a wide variety of sizes,forms and shapes. In a preferred embodiment, the elastomeric material124 is in the form of a continuous plane layer. Preferred forms ofcontinuous plane layer include a scrim, a perforated (or aperturesformed) film, an elastomeric woven or nonwoven, and the like. Thecontinuous plane layer may take any shape which can be suitably providedin the ear panels. Preferred shapes of continuous plane layer include aquadrilateral including a rectangle and a square, a trapezoid, and theother polygons. In an alternative embodiment, the elastomeric material124 is in the form of discrete strands (or strings) which are notconnected each other.

Elastomeric materials which have been found to be especially suitablefor the elastomeric material 124 are styrenic block copolymer basedscrim materials, perforated (or apertured) elastic films, preferablywith a thickness of from about 0.05 mm to about 1.0 mm (0.002 inch-0.039inch). Other suitable elastomeric materials for the elastomeric material124 include “live” synthetic or natural rubber, other synthetic ornatural rubber foams, elastomeric films (including heat shrinkableelastomeric films), elastomeric woven or nonwoven webs, elastomericcomposites, or the like.

In a preferred embodiment, the elastomeric material 124 is a porous,macroscopically-expanded, three-dimensional elastomeric web 172 as shownin FIG. 9. The web 172 has a continuous first surface 174 and adiscontinuous second surface 176 remote from first surface 174. Theelastomeric web 172 preferably comprises a formed film having at leasttwo polymeric layers, with at least one of the layers being an elastomerlayer 178 and at least one of the other layers being a substantiallyless elastomeric skin layer 182. The elastomeric web exhibits amultiplicity of primary apertures 184 in the first surface 174 of theweb 172, the primary apertures 184 being defined in the plane of thefirst surface 174 by a continuous network of interconnecting members186. Each interconnecting member 186 exhibits an upwardly concave-shapedcross-section along its length. The interconnecting members 186terminate substantially concurrently with one another to form asecondary aperture 188 in the plane of the second surface of the web.The primary apertures 184 may have any shape. The detail of such astructure and the method to manufacture is disclosed in U.S. patentapplication Ser. No. 08/816,106, filed Mar. 14, 1997. A preferred porouselastomeric material 124 is manufactured by the Tredegar Film Productsunder the designation X-25007.

The extension properties of the side elastomeric material 124 such asthe First Cycle Extension Force at 100% Extension (FCEF100%), the FirstCycle Extension Force at 200% Extension (FCEF200%), the Second CycleRecovery Force at 50% Extension (SCRF50%) and sustained load at 50%after 10-12 hours are important considerations in the performance ofdisposable garments. The side elastomeric material 124 preferably hasextension properties within the defined ranges herein. The FCEF100% andthe FCEF200% are measures of the overall perceived “stretchiness” duringapplication/removal of disposable garments. These two properties alsoaffect the ability of the applicator to achieve a suitable degree ofapplication stretch. A side elastomeric material 124 with a relativelyhigh FCEF100% and FCEF200% can cause difficulty in applying thedisposable garment onto the wearer. On the other hand, a sideelastomeric material 124 with a relatively low FCEF100% and FCEF200% maynot achieve a suitable level of body fitting/conformity. The SCRF50%also closely relates to the body fitting/conformity of disposablegarments for the wearer. A side elastomeric material 124 with arelatively high SCRF50% tends to cause red marking on the skin of thewearer and may be uncomfortable for the wearer during usage. A sideelastomeric material 124 with a relatively low SCRF50% may not provideenough elastic force to keep the diaper in place on the wearer or maynot provide good body fit. The sustained load at 50% after 10-12 hoursevaluates the force decay over time. This force decay should be limitedor substantial sagging will result.

The values of FCEF100%, FCEF200% and SCRF50% can be measured by using atensile tester. The tensile tester includes an upper jaw and a lower jawwhich is located below the upper jaw. The upper jaw is movable and isconnected to an extension force measuring means. The lower jaw is fixedat a desk (or floor). A test specimen (i.e., the elastomeric material tobe measured) which has about 2.54 cm (1.0 inch) in width and about 12.75cm (5 inches) in length is prepared and clamped between the upper jawand the lower jaw so that the effective specimen length (L) (i.e., gaugelength) is about 5.08 cm (2.0 inches). The extension force is applied tothe test specimen through the upper jaw. When no extension force isapplied to the test specimen, the test specimen is in its originallength (i.e., 0% extension). A tensile tester suitable for use herein isavailable from Instron Corporation (100 Royall Street, Canton, Mass.02021, U.S.A.) as Code No. Instron 5564.

FIG. 8 shows one preferred example of the extension and recovery forcecurves for the two cycle hysteresis of the elastomeric material 124. Thecurve E1 shows the extension force in the first cycle, while the curveR1 shows the recovery force in the first cycle. The curve E2 (shown indashed lines) shows the extension force in the second cycle, while thecurve R2 shows the recovery force in the second cycle. The extension andrecovery properties are measured as follows.

In the first cycle, the test specimen is subjected to an initialextension force at a crosshead rate of 50.8 cm/min (20 in/min) at about23° C. and held for 30 seconds at 200% extension. The test specimen isthen allowed to relax at the same rate to the original state (i.e., 0%extension). The test specimen is allowed to remain unconstrained for oneminute before being subjected to a second extension force (for thesecond cycle) at the same rate and conditions.

In preferred embodiments, the FCEF100% of the side elastomeric material124 is at least about 100 grams/inch. More preferably, the FCEF100% isbetween about 120 to about 220 grams/inch, most preferably between about150 grams/inch and 190 grams/inch. The FCEF200% is preferably betweenabout 160 grams/inch and about 450 grams/inch, more preferably betweenabout 180 grams/inch and about 300 grams/inch, and yet more preferablybetween about 200 grams/inch and about 240 grams/inch. The SCRF50% ofthe side elastomeric material 124 is preferably between about 40grams/inch and about 130 grams/inch, more preferably between about 65grams/inch and about 105 grams/inch, and yet more preferably betweenabout 75 grams/inch and about 95 grams/inch. The sustained load at 50%after 10-12 hours is preferably between about 40 grams/inch and about130 grams/inch, more preferably between about 65 grams/inch and about105 grams/inch, and yet more preferably between about 75 grams/inch andabout 95 grams/inch.

In the preferred embodiment shown in FIG. 6, the elastomeric scrim 124has a plurality of first strands 125 and a plurality of second strands127. The plurality of first strands 125 intersect the plurality ofsecond strands 127 at nodes 130 at a predetermined angle a, forming anet-like open structure having a plurality of apertures 132. Eachaperture 132 is defined by at least two adjacent first strands and atleast two adjacent second strands, so that the apertures 132 aresubstantially rectangular in shape. Other configurations of theapertures 132, such as parallelograms, squares, or circular arcsegments, can also be provided. Preferably, the first and second strands125 and 127 are substantially straight and substantially parallel to oneanother. Preferably, the first strands 125 intersect the second strands127 at nodes 130 such that the angle α is about 90 degrees. The firstand second strands 125 and 127 are preferably joined or bonded at nodes90.

A preferred elastomeric scrim 124 is manufactured by the Conwed PlasticsCompany (Minneapolis, Minn., U.S.A.) under the designation XO2514. Thismaterial has about 12 elastic strands per inch in the structuraldirection B (i.e., the first strands 125) and about 7 elastic strandsper inch in the structural direction D (i.e., the second strands 127).

In the embodiment shown in FIG. 6, the elastic member 70 includes firstand second coverstock layers 122 and 126, and elastomeric material 124disposed in the first and second coverstock layers 122 and 126. Thefirst coverstock layer 122 has an inner surface 142 and an outer surface144. The inner surface 142 of the first coverstock layer 122 is thesurface that is positioned facing the elastomeric material 124. Thesecond coverstock layer 126 also has an inner surface 146 and an outersurface 148. The inner surface 146 of the second coverstock layer 126 isthe surface that is positioned facing the elastomeric material 124. Theelastomeric material 124 also has two planar surfaces, first surface 150and second surface 152, each of which is substantially parallel with theplanes of the first and second coverstock layers 122 and 126. The firstsurface 150 is that planar surface of the elastomeric material 124 thatis most closely adjacent with the inner surface 142 of first coverstocklayer 122. The second surface 152 is that planar surface of elastomericmaterial 124 that is most closely adjacent to the inner surface 146 ofthe second coverstock layer 126.

Since the elastic member 70 will be subjected to mechanical stretchingbefore and during use, the first and second coverstock layers 122 and126 preferably have a relatively high elongation at breaking, and aremore preferably stretchable or elongatable, yet more preferably drawable(but not necessarily elastomeric), without undue (and preferably withoutany), tearing or ripping. Further, the first and second coverstocklayers 122 and 126 are preferably compliant, soft feeling, andnon-irritating to the wearer's skin and give the article the feel andcomfort of a cloth garment. Suitable materials for the first and secondcoverstock layers 122 and 126 can be manufactured from a wide range ofmaterials such as plastic films, apertured plastic films, woven ornonwoven webs of natural fibers (e.g., wood or cotton fibers), syntheticfibers (e.g., polyolefins, polyamides, polyester, polyethylene, orpolypropylene fibers), or a combination of natural and/or syntheticfibers, or coated woven or nonwoven webs.

Preferably, each of the first and second coverstock layers 122 and 126is an identical consolidated nonwoven material. An exemplary preferrednonwoven material is manufactured by the Fiberweb North America, Inc.(Simpsonville, S.C., U.S.A.) under the designation Sofspan 200. Thismaterial has a basis weight of 25 g/m² before consolidation and a basisweight of about 63 g/m2 after consolidation. Herein, “basis weight” isthe weight of one square meter of planar web material. Alternatively,highly strainable nonwoven materials may be used. Alternatively, thefirst and second coverstock layers 122 and 126 need not be of identicalmaterials, as long as the desired performance requirements, such aselastic performance, softness, flexibility, breathability anddurability, are met. Herein, “consolidated nonwoven material” means anonwoven material that has been gathered or necked under mechanicaltension in the structural direction D so that the material can elongatein the structural direction D under low force.

FIG. 7 shows a fragmentary enlarged side view looking into thestructural direction B of the laminate 120 (i.e., the elastic member70). It has been found that when the laminate 120 is bonded or otherwiseanchored such that side anchor zones A are created, such a laminate 120is both highly elastic and substantially free from delamination andcreep, while providing very good performance characteristics in allperformance categories with no trade-offs between any performancecharacteristics required. The side anchoring is preferably performed byside gluing with adhesive beads to anchor the elastomeric material 124between the coverstock layers 122 and 126 as a part of the laminationprocess. Alternatively, side anchoring may be performed by sewing, heatsealing, ultrasound bonding, needle punching, alternative gluingprocesses, or by any other means known to those skilled in the art.Another alternative is to side anchor the layers of the laminatestructure after the lamination of the elastomeric and coverstockcomponents has been performed.

Preferably, the laminate 120 may particularly provide very good softfeel for the wearer and for the consumer. This is important becauseconsumers value softness. In conventional laminates, the attempts toeliminate creep have frequently required an unacceptable decrease insoftness, often accompanied by an unacceptable decrease in an ability toactivate. This is because such previous attempts (which have fallenshort of eliminating creep) have focused on the application ofadditional melt blown adhesive, often in an overall coating pattern, inthe attempt to strengthen the bonds. This has generally resulted in anundesirable overall stiffening of the laminate. However, the laminatesof the preferred embodiments provide elimination of creep without theloss of consumer-desired soft feel and without compromise of activationability.

Referring to FIG. 7, a first adhesive 170 is applied to the innersurface 146 of the second coverstock layer 126 in positions thatcorrespond to each of the outer edges 180 of the laminate structure 120.The first adhesive 170 may alternatively or additionally be applied tothe inner surface 142 of the first coverstock layer 122. For ease ofillustration, the description and Figs. refer to application to thesecond coverstock layer 126 only.

This pattern creates side anchor zones A, which substantially eliminatethe delamination and creep associated with previously known laminatesand which allows the laminate 120 to experience higher strains withoutcreeping or delaminating. It has also been found that confining thefirst adhesive 170 to the edge areas 180 of the laminate structure 120avoids impeding the extensibility of the laminate 120 and also avoidstears in the coverstock layers 122 and 126. Preferably, the firstadhesive 170 is applied as a plurality of beads 168, as shown in FIG. 7.Preferably, the first adhesive 170 is a flexible adhesive with anamorphous and crystallizing component. Such a preferred adhesive is madeby Nitta Findley Co., Ltd., Osaka, Japan, under the designation H9224.

More preferably, the laminate 120 includes a second adhesive 164. Thesecond adhesive 164 is preferably applied to the second surface 152 ofthe elastomeric material 124, but could alternatively be applied to thefirst surface 150 of the elastomeric material 124. The second adhesive164 is preferably applied in a spiral spray pattern 166, thereby formingbond points 167b that are more discrete than would be formed by a linearspray application. Without being bound by theory, it is believed thatmost of the second adhesive 164 is sprayed in the structural direction D(FIG. 6). Thus, it has been found that spiral spraying results in verygood activation properties. Herein, “activation” refers to the abilityto stretch.

It has been found that spraying the layer of second adhesive 164directly onto the second surface 152 of the elastomeric material 124 ismore preferable than applying the second adhesive 164 to the opposing(i.e., second) coverstock layer 126. This is because the second adhesive164 tends to penetrate through any residual processing agents or oilsthat may remain on the surface of the elastomeric material 124. Suchresidual materials, if left to remain on the elastomeric material 124,may weaken the adhesive bonds and thus the laminate structure 120 overtime. For example, if these residual materials are left intact, thebonds used to form the laminate 120 may weaken during the time intervalprior to consumer purchase of the product.

Peel values for the laminate 120 in the spiral adhesive areas aretypically higher when the spirals 166 are applied directly to theelastomeric material 124 than to the opposing (i.e., second) coverstocklayer 126. Herein, “peel value” refers to the amount of force requiredto separate the two layers of coverstock material, 122 and 126, fromeach other. Higher peel values typically equate to less chance ofdelamination in use.

A third adhesive 160 may also preferably be applied to the inner surface142 of the first coverstock layer 122. Preferably, the third adhesive160 is an elastomeric adhesive. In a manner similar to that describedwith reference to the second spiral adhesive application 166, the firstadhesive 160 is preferably applied in a spiral spray pattern 162,thereby forming bond points 167 a that are more discrete than would beformed by a linear spray application. Without being bound by theory, itis believed that most of the first adhesive 160 so sprayed aligns in thestructural direction D.

Preferably, second and third adhesives 160 and 164 are the sameelastomeric adhesive. A preferred adhesive for use in the second andthird adhesive spiral sprays 162 and 166 is made by Nitta Findley Co.,Ltd., Osaka, Japan, under the designation H2120. Preferably, the add-onlevel for each of the second and third spiral sprays 162 and 166 isabout 4 to about 12 milligrams per square inch, more preferably about 8milligrams per square inch.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A disposable pull-on diaper comprising: a liquidpervious topsheet; a liquid impervious backsheet; an absorbent coredisposed between the topsheet and the backsheet; a front region; a backregion; a side; a first extensible ear panel extending outwardly fromthe side in the front region, wherein the first extensible ear panel isa discrete element and is joined to the side, wherein the firstextensible ear panel comprises: a first nonwoven material; a secondnonwoven material; and an apertured film positioned at least partiallyintermediate the first and second nonwoven materials; a secondextensible ear panel extending outwardly from the side in the backregion, wherein the second extensible ear panel is a discrete elementand is joined to the side, wherein the second extensible ear panelcomprises: a first nonwoven material; a second nonwoven material; and anapertured film positioned at least partially intermediate the first andsecond nonwoven materials; a butt seam joining the first and secondextensible ear panels to form a leg opening; an elasticized waistband inthe front region; a first leg cuff; and a second leg cuff; wherein afirst portion of the elasticized waistband overlaps a first portion ofthe first leg cuff; and wherein a second portion of the elasticizedwaistband overlaps a first portion of the second leg cuff.
 2. Thepull-on diaper of claim 1, wherein the butt seam comprises a pattern ofheat or pressure welds.
 3. The pull-on diaper of claim 1, wherein thebutt seam comprises a pattern of ultrasonic welds.
 4. The pull-on diaperof claim 1, comprising a second side, and wherein the pull-on diapercomprises: a third extensible ear panel extending outwardly from thesecond side in the front region, wherein the third extensible ear panelis a discrete element and is joined to the second side, and wherein thethird extensible ear panel comprises: a first nonwoven material; asecond nonwoven material; and an apertured film positioned at leastpartially intermediate the first and second nonwoven materials; a fourthextensible ear panel extending outwardly from the second side in theback region, wherein the fourth extensible ear panel is a discreteelement and is joined to the second side, and wherein the fourthextensible ear panel comprises: a first nonwoven material; a secondnonwoven material; and an apertured film positioned at least partiallyintermediate the first and second nonwoven materials; and a second buttseam joining the third and fourth extensible ear panels to form a secondleg opening.
 5. The pull-on diaper of claim 4, wherein the second buttseam comprises a pattern of heat or pressure welds.
 6. The pull-ondiaper of claim 4, wherein the second butt seam comprises a pattern ofultrasonic welds.
 7. The pull-on diaper of claim 1, comprising a secondelasticized waistband in the back region.
 8. The pull-on diaper of claim7, wherein a first portion of the second elasticized waistband overlapsa second portion of the first leg cuff, and wherein a second portion ofthe second elasticized waistband overlaps a second portion of the secondleg cuff.
 9. The pull-on diaper of claim 7, wherein a portion of theelasticized waistband overlaps a portion of the first extensible earpanel, and wherein a portion of the second elasticized waistbandoverlaps a portion of the second extensible ear panel.
 10. The pull-ondiaper of claim 1, wherein a portion of the backsheet overlaps with aportion of the first extensible ear panel.
 11. The pull-on diaper ofclaim 1, wherein a portion of the backsheet extends into the firstextensible ear panel.
 12. The pull-on diaper of claim 11, wherein aportion of the backsheet extends into the second extensible ear panel.13. The pull-on diaper of claim 12, wherein the first portion of thefirst leg cuff overlaps a portion of the first extensible ear panel. 14.A disposable diaper comprising: a liquid pervious topsheet; a liquidimpervious backsheet; an absorbent core disposed between the topsheetand the backsheet; a front region; a back region; and a side; a discretefirst ear panel extending outwardly from the side in the front region,wherein the first ear panel comprises: a first nonwoven material; asecond nonwoven material; and a perforated film positioned at leastpartially intermediate the first and second nonwoven materials; adiscrete second ear panel extending outwardly from the side in the backregion, wherein the second ear panel comprises: a first nonwovenmaterial; a second nonwoven material; and a perforated film positionedat least partially intermediate the first and second nonwoven materials;a butt seam joining the discrete first and second ear panels to form aleg opening; and an elasticized waistband on a wearer-facing surface ofthe diaper; wherein a portion of the elasticized waistband overlapseither a portion of the discrete first ear panel or a portion of thediscrete second ear panel; and wherein a portion of the elasticizedwaistband overlaps a portion of a leg cuff, and wherein the portion ofthe leg cuff overlaps either a portion of the discrete first ear panelor a portion of the discrete second ear panel.
 15. The diaper of claim14, wherein the butt seam comprises a pattern of heat or pressure weldsor a pattern of ultrasonic welds.
 16. The diaper of claim 14, comprisinga second elasticized waistband on a wearer-facing surface of the diaper.17. The diaper of claim 14, comprising a second side, and wherein thediaper comprises: a discrete third ear panel extending outwardly fromthe second side in the front region, wherein the third ear panelcomprises: a first nonwoven material; a second nonwoven material; and aperforated film positioned at least partially intermediate the first andsecond nonwoven materials; a discrete fourth ear panel extendingoutwardly from the second side in the back region, wherein the fourthear panel comprises: a first nonwoven material; a second nonwovenmaterial; and a perforated film positioned at least partiallyintermediate the first and second nonwoven materials; and a second buttseam joining the discrete third and fourth extensible ear panels to forma second leg opening; and a second elasticized waistband on thewearer-facing surface of the diaper.
 18. The diaper of claim 17, whereinthe second butt seam comprises a pattern of heat or pressure welds or apattern of ultrasonic welds.
 19. The diaper of claim 14, wherein aportion of the liquid impervious backsheet extends to a portion of thefirst ear panel.
 20. The diaper of claim 14, wherein a portion of theliquid impervious backsheet overlaps with a portion of the first earpanel.
 21. The diaper of claim 17, wherein the discrete first and thirdear panels have substantially the same size and shape.
 22. The diaper ofclaim 17, wherein the discrete second and fourth ear panels havesubstantially the same size and shape.
 23. The diaper of claim 14,comprising an acquisition/distribution core positioned over theabsorbent core.
 24. The diaper of claim 14, comprising a second legcuff, wherein the elasticized waistband overlaps a portion of the secondleg cuff.
 25. A disposable pull-on diaper comprising: a liquid pervioustopsheet; a liquid impervious backsheet; an absorbent core disposedbetween the topsheet and the backsheet; a front region; a back region; aside; a first extensible ear panel extending outwardly relative to theside in the front region, wherein the first extensible ear panel is adiscrete element and is joined to the side, wherein the first extensibleear panel comprises: a first nonwoven material; a second nonwovenmaterial; and an apertured or perforated material positioned at leastpartially intermediate the first and second nonwoven materials; a secondextensible ear panel extending outwardly relative to the side in theback region, wherein the second extensible ear panel is a discreteelement and is joined to the side, wherein the second extensible earpanel comprises: a first nonwoven material; a second nonwoven material;and an apertured or perforated material positioned at least partiallyintermediate the first and second nonwoven materials; and a butt seamjoining the first and second extensible ear panels to form a legopening; a first elasticized waistband in the front region; and a secondelasticized waistband in the back region; wherein a portion of thebacksheet extends to the first extensible ear panel; and wherein aportion of the backsheet extends to the second extensible ear panel. 26.The pull-on diaper of claim 25, wherein a portion of the firstelasticized waistband overlaps a portion of the first extensible earpanel, and wherein a portion of the second elasticized waistbandoverlaps a portion of the second extensible ear panel.
 27. The pull-ondiaper of claim 25, comprising a leg cuff, wherein a portion of thefirst elasticized waistband overlaps a portion of the leg cuff.
 28. Thepull-on diaper of claim 27, comprising a second leg cuff, wherein aportion of the second elasticized waistband overlaps a portion of thesecond leg cuff.
 29. A disposable pull-on diaper comprising: a topsheet;a backsheet; an absorbent core disposed between the topsheet and thebacksheet; a front region; a back region; a side; a discrete firstextensible ear panel extending outwardly from the side in the frontregion, wherein the discrete first extensible ear panel is joined to theside, wherein the first extensible ear panel comprises: a first nonwovenmaterial; a second nonwoven material; and an apertured or perforatedmaterial positioned at least partially intermediate the first and secondnonwoven materials; a discrete second extensible ear panel extendingoutwardly from the side in the back region, wherein the discrete secondextensible ear panel is joined to the side, wherein the secondextensible ear panel comprises: a first nonwoven material; a secondnonwoven material; and an apertured or perforated material positioned atleast partially intermediate the first and second nonwoven materials; abutt seam comprising a plurality of bonds joining the discrete first andsecond extensible ear panels to form a leg opening; and an elasticizedwaistband on a wearer-facing surface of the diaper, wherein theelasticized waistband overlaps a portion of the discrete firstextensible ear panel or a portion of the discrete second extensible earpanel; wherein the backsheet extends to the first extensible ear panel.30. The pull-on diaper of claim 29, wherein the elasticized waistband isin the front region, and wherein a portion of the elasticized waistbandoverlaps a first portion of a leg cuff.